P.T.

CENTRALJAVAPOWER SUMITOMOCORPORATION
Project:

TANJUNGJATI'B'COALFIREDPOWERSTATION UNITS3&42X660MW(NET)

DocumentTitle:

SHOPINSPECTIONANDTESTPROCEDURE FOR CONTINUOUSEMISSIONMONITORINGSYSTEM

DocumentNo.:

BuyersDocumentNo.: 7131506.FAT.01

SICKSDocumentNo.:

0 Version Submittedby:

Jerry Yang Prepared by Reviewed by

Mi zhengqian Approved by Approved Date

SICK MAIHAK(Beijing)Co.,Ltd

 7131506.FAT.01

Table of contents

1. Purpose 2. System configuration of FAT of CEMS 3. Certificates of Calibration Instruments 4. Calibration Certificate of Gas Analyzer and FlowSIC100 5. Reference Drawings 6. Test and Inspection items 7. Test and Inspection Procedures

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1. Purpose The project locates at Tanjung Jati, Central Java,Indonesia, SICKMAIHAI (Beijing) will supply 2 set of SMC-9021 system for SO2/NO2/CO/CO2 emission monitoring. This document describes the test and inspection contents and procedure of CEMS (Continuous Emission Monitoring System) for Tanjun-Jati B Coal-Fired Power Station Unit 3 & 4 2 x 660 MW. This test and inspection confirms that the customer requirement and the standard of our company are satisfied fundamentally. This procedure will be applied to FAT for CEMS 1.1 Test place Address:No. 160 Beijing Road, Wenquan Haidian District, Beijing, 100095 P.R.China Place: SICKMAIHAK (BEIJING) Co., Ltd. 1.2 Test Schedule No 1 2 3 Equipment Hardware Equipments Gas Analyzer Calibration Test CEMS Function Test Test Item Hardware Inspection Calibration Report Checking Function Test Plan of Completion date Apr. 1th 2th, 2010 Apr. 1th 2th, 2010 Apr. 1th 2th, 2010

2 System configuration of FAT of CEMS Unit3 Unit4

Local CCR

3 Certificates of Calibration Instruments Name Insulation Meter Pressure Meter Oxygen Meter Universal Meter Type/Serial No. ZC25-4/092983 (0-0.16Mpa)/2528 (0-25Mpa)/2007121097 UT58E/3060247904 Certificate No. D210J-B0074 09038971 10005356 D110Z-A0101
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Conclusion Grade 10.0 Grade 2.5 Grade 2.5

Comment See Annex 1 See Annex 2 See Annex 3 See Annex 4

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4. Calibration Certificate of Gas Analyzer and FlowSIC100 Name Gas Analyzer Type/Serial No. S710/ Measuring range SO2: 0-500-2000mg/m3 NO:0-1000mg/m3 CO:0-1000mg/m3 CO2:0-20% SO2: 0-500-2000mg/m3 NO:0-1000mg/m3 CO:0-1000mg/m3 CO2:0-20% Calibration Report See Annex 5

Gas Analyzer

S710/

See Annex 6

Flow meter Flow meter

Flowsic100/10048555 Flowsic100/10048556

See Annex 7 See Annex 8

5. Reference Drawings ISSUE NO. 3 3 3 3 3 3 3 3 3 1 3 3 3 3 3 3 2 2 2 2 2 1 1 SUBMITTAL DATE 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100122 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112 20100112

DWGNO.
7131506.00001 7131506.00002 7131506.00003 7131506.00004 7131506.00005 7131506.00006 7131506.00007 7131506.00008 7131506.00009 7131506.00010 7131506.00011 7131506.00013 7131506.00015 7131506.00016 7131506.00017 7131506.00018 7131506.00019 7131506.00021 7131506.00023 7131506.00024 7131506.00025 7131506.00028 71315026.00029

TITLE
CEMSsystemconfigurationdrawing CEMSenclosurelayoutdrawing Samplingprobeflangeinstallationdrawing TemperatureprobeflangeInstallationdrawing Pressureprobeflangeinstallationdrawing Spareinstallationdrawing FlowAnalyzerInstallationdrawing CEMSMeasurepointlayoutdrawing CEMSsystemflowchart Unit4CEMSsystemflowchart(Notused) Powersupplyandairallotmentdiagram CEMSpowersupplysystemdrawing Unit3CEMSsignalterminalwiringdrawing Unit4CEMSsignalterminalwiringdrawing Oxygenprobeflangeinstallationdrawing Cableductwork Paneloutlinedimensiondrawing Controlpanellayoutdrawing Panelexternalconnectiondiagram Paneltubingandpipingdrawing Panelinternalarrangementdrawing FlowanalyzerControlunitLayoutdrawing OxygenanalyzerControlunitLayoutdrawing

6. Test and Inspection Items

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Item 1 2 3

Category Hardware Inspection Documentation audit Function Test inspection

Inspection means By witness By certificate / report audit By Testing

7.Test and Inspection Procedures 7.1 Procedures Reference document and/or acceptance standard

Inspection by Witness Record Sick Maihak B &V SC/Fic htner

No.

Equipment Component

Witness Items

1. 1.1

Hardware Inspection S710 gas analyzer S710 3EVM-AX801 4EVM-AX801 Normal structure checking, appearance checking Document of <Q/SMC Quality control of Supply chain management> Method: By witness Comply with: contract document and technical specifications, Conclusion: OK if no damage on surface

1.3

FlowSICK100 3EVM-FX801 4EVM-FX801

Normal structure checking, appearance checking

Document of <Q/SMC Quality control of Supply chain management>

Method: By witness Comply with: contract document and technical specifications, Conclusion: OK if no damage on surface

1.4

ZR22G Oxygen analyzer 3EVM-AX802 3EVM-AX802

Normal structure checking, appearance checking

Document of <Q/SMC Quality control of Supply chain management>

Method: By witness Comply with: contract document and technical specifications,

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No.

Equipment Component

Witness Items

Reference document and/or acceptance standard

Inspection by Witness Record Sick Maihak B &V SC/Fic htner

Conclusion: OK if no damage on surface 1.5 Temp sensor 3EVM-TX801 4EVM-TX801 Normal structure checking, appearance checking Document of <Q/SMC Quality control of Supply chain management> Method: By witness Comply with: contract document and technical specifications, Conclusion: OK if no damage on surface 1.6 Pressure transmitter 3EVM-PX801 4EVM-PX801 Normal structure checking, appearance checking Document of <Q/SMC Quality control of Supply chain management> Method: By witness Comply with: contract document and technical specifications, Conclusion: OK if no damage on surface 1.7 AB PLC Normal structure checking, appearance checking Document of <Q/SMC Quality control of Supply chain management> Method: By witness Comply with: contract document and technical specifications, Conclusion: OK if no damage on surface 1.8 Sampling line Normal structure checking, appearance checking Document of <Q/SMC Quality control of Supply chain management> Method: By witness Comply with: contract document and technical specifications, Conclusion: OK if no damage on surface 2.

Documentation audit

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No.

Equipment Component

Witness Items

Reference document and/or acceptance standard

S700 analyzer

Inspection by Witness Record Sick Maihak B &V SC/Fic htner

1)

Measuring range check, 1)Comply with

2) S710 2.1 analyzer gas 3)

Linearization checking; Zero-point full-range calibration; and

calibration manual

contract and technical specification

2)S700 analyzer calibration report

4)

Stability checking;

1)insulation resistance testing 2) FlowSICK 100 2.2 3EVM-FX801 4EVM-FX801 Length, angle, area

1)Comply

with

contract and technical specification

cross-sectional setting

3)parameter setting 4)unit checking 5) analog signal

2)Flowsic100 Testing Report

checking AB 2.3 controller IO module PLC and

TYPE approval certificate

2.4

Condenser Mak10

Quality Certificate

1)Quality Certificate Temperature 2.5 transmitter 3EVM-TX801 4EVM-TX801

2) Logistic checking record before registering into ERP system and put into warehouse

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No.

Equipment Component

Witness Items

Reference document and/or acceptance standard

Inspection by Witness Record Sick Maihak B &V SC/Fic htner

1)Quality Certificate Pressure 2.6 transmitter 3EVM-PX801 4EVM-PX801

2) Logistic checking record before registering into ERP system and put into warehouse Production Record of

Cabinet 2.7 3EVM-PAN801 4EVM-PAN801

Cabinet assembly, wiring and Function Test.

2.8

Documents and Drawings

Documents and Drawing reviewing

3. Function Test inspection

Pipeline leak testing checking. 3.1 CEMS system Function Documents SMC-9021 CEMS system Test of Please refer 7.2.4

Function CEMS system

test

Function Documents SMC-9021

Test of Press relative buttons on panel.

(auto/manu switching, 3.2 sampling, purging)

CEMS system

IO signal checking

Function Documents

Test of Please refer 7.2.5

3.3

AB PLC

SMC-9021 CEMS system

Testing with sample gas 3.4 CEMS system checking, checking). (zero-point Full-range

Function Documents SMC-9021

Test of Please Refer 7.2.3

CEMS system

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7.2 Detailed Procedures

7.2.1 Linearity (this procedure was used during Gas analyzer calibration):
Calibration equipment: Method: 1. Precise proportional pump 2. Span gas 1. Measuring 5 different point of span gas with different concentration (0%, 20%, 40%, 80%, 100%). 1. Calculating error for these 5 points [(Measuring value Span value)/max limit of Span gas] Result: 1. Linearity will be marked OK if error of all 5 points are less than 2% (compared to max range limit) 2. Linearity will be marked Not OK if any error of 5 points is high than 2% (compared to max. range limit)

7.2.2 Stability (this procedure was used during Gas analyzer calibration):
Calibration equipment: 1. Zero gas 2. Span gas Method: 1. connecting Zero gas, waiting until the display reading become stable, writing down the display reading. 2. Connecting Span gas (concentration is between 90% 105% of max range limit), waiting until the display reading becomes stable, writing down the display reading. 3. Repeating step 1) and 2) for 5 continuous days. 4. Calculating error for 5 days display readings. Result: StabilitywillbemarkedOKifallcalculatederrors arelessthan 1.5%(comparedtomax.rangelimit)

7.2.3 Calibration of Zero Point and Max limit point:

Calibration equipment: 1. Zero gas 2. Span gas Method: 7.2.4 Gas leaking test 1. Compress air 2. Pressure meter Method: 1. Connecting compress air(0.08Mpa) to inlet pipe. 2. Waiting10minutes.
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1.

Connecting Zero gas for Zero point calibration.

2. ConnectingSpangasforMax.limitpointcalibration

Calibration equipment:

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3. Monitoring outlet pressure of Drain pipe Result 1. OK if pressure decline is less than 0.005Mpa within 10 minutes

7.2.5 PLC IO checking:

Calibration equipment: 1. Universal meter, Type: UNI-T.

Method:

1. Setting target value (full range value) in PLC 2. Measuring output current by universal meter.

Result

OK if output current error is less than 0.5%

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Annex 1

Annex 2

Annex 3

Annex 4

Annex 7

Annex 8